TD5 EGR bypass

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GDM

Active Member
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205
Location
West Sussex
Our TD5 needs a bit of money spending on it, so I was thinking of doing an EGR bypass along with all of the other bits (new shocks, steering damper, front propshaft, fixing the leaking sunroofs etc.).

I fitted one to our old E46 BMW 320d which had a stub on the side to which the pipe from the exhaust manifold attached but which effectively blanked the pipe off.

I am a bit nervous of removing the pipe from the exhaust manifold on the TD5 as the bolts are difficult to get at and likely to shear off. Is there a kit available like the BMW type which would avoid messing about with the exhaust manifold?

Thanks.
 
GDM said:
Our TD5 needs a bit of money spending on it, so I was thinking of doing an EGR bypass along with all of the other bits (new shocks, steering damper, front propshaft, fixing the leaking sunroofs etc.).

I fitted one to our old E46 BMW 320d which had a stub on the side to which the pipe from the exhaust manifold attached but which effectively blanked the pipe off.

I am a bit nervous of removing the pipe from the exhaust manifold on the TD5 as the bolts are difficult to get at and likely to shear off. Is there a kit available like the BMW type which would avoid messing about with the exhaust manifold?

Thanks.
Click to expand...
i thought the same when doing mine but was dead easy to undo just need a hex set the fits into a socket set jobs a good'un.
you could always put the blanking plate on the end of the EGR cooler instead.
 
i just fit a blank plate in between manifold and pipe ,usually a few taps on allen bolts loosens them but you could blank the other end
 
Thanks for the replies.

I will have to start dousing the bolts with 3 in 1 regularly, and hope that they come out alright.

There is no cat on our car anyway, as it is a 1999 model.

Understood about all the sh*te entering the engine, that's one of the main reasons I did it on the 320d. It did seem to improve the fuel economy on that, and it made it less prone to stalling and smoother at below 2000 RPM.
 
In my case, after bypassing the EGR, the noise level at idle speed is higher, and the smoothness in general is lower. I want to make tests re-fitting it now, that I have a Stage II map on it, and take notes to the feel of the engine. I will see.
 
GDM said:
Thanks for the replies.

I will have to start dousing the bolts with 3 in 1 regularly, and hope that they come out alright.

There is no cat on our car anyway, as it is a 1999 model.

Understood about all the sh*te entering the engine, that's one of the main reasons I did it on the 320d. It did seem to improve the fuel economy on that, and it made it less prone to stalling and smoother at below 2000 RPM.
Click to expand...

3 in 1 is better than the usual idea of WD40, but you should really be using a proper penetrating/releasing oil such as PlusGas or similar.

Make sure that your allen key fits the bolt head socket correctly; if you start rounding that you could have some difficulty.
 
I didn't realise PlusGas was still available, in that case I will pick up a can.

Personally I think WD40 is rubbish, it seems to evaporate off in about 5 minutes, it really is only good as a water dispersant.

I have several good sets of allen keys, so no worries there.
 
and has been suggested by others. definately give the heads of the bolts a sharp tap with a hammer.
and as for penetrating fluid. i use a mixture of acetone and atf. 50/50 mix. i keep it in a plastic bottle with a spray head.
 
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